The SETUP page consists of four basic pages which are mainly used to define data such as scrap, tool, dummy tool, plant line, etc. including the setup of parameters such as model data and initial velocity.
Once the stamped part data are imported, perform part mesh and mesh check/repair to strictly control the mesh quality. Then pick the outline and related trim line of scrap, and use them to trim the stamped part to obtain the scrap to be analyzed.
Since the shedding condition for each scrap is different during calculation, the user needs to put each scrap on a different layer, and set color for each scrap, then define the material parameters respectively.
In Scrap Setup interface, the user can define Part, Material and Thickness, move and display scrap, define contact, and define single point constraint.
GEOMETRY
PARTS
Enables the user to define scrap by selecting Part or directly import mesh file, as illustrated in Figure 10.2.4. After clicking the Define geometry… button, the program will pop up a DEFINE GEOMETRY dialog box, as illustrated in Figure 10.2.5.
Figure 10.2.4 Scrap parts
Figure 10.2.5 Define scrap
ADD PART…: Select one or multiple parts to define scrap. The selected parts will be displayed in Part List.
REMOVE PART: Remove the selected parts from Part List.
ADD ELEM…: Add the selected element to the current selected part.
COPY ELEM…: Copy or offset a new element from the existing element. The new element will be added to a default part and this part will be named as Scrap.
SPLIT PART: Split scrap into multiple pieces of scrap and define different material and property for each piece of scrap.
DISPLAY: Display all the parts defined in the part list for the user to check and repair mesh.
EXIT: Exit the Define Scrap dialog box.
Once the scrap parts are defined, all the defined parts will display under the Part label. At present, the program has already defined the default material, thickness and property automatically for each scrap part. The user can modify these default material, thickness and property according to the practical situation.
MATERIAL
The program will define a default 18# material for each defined scrap part, as illustrated in Figure 10.2.6.
Figure 10.2.6 Scrap material
NOTE: if the user does not specify material for scrap, BLANKMAT will display on the Define Material button. Once the material is specified for the scrap, the material name will display on this button.
Individual: modify the material type for individual scrap or all scraps. If this option is toggled on, the user is allowed to define different material type for each scrap. If this option is not toggled on, the material type of all the other scraps will change when the material type of one scrap is defined or modified, namely, define one scrap, then define all.
The user can enter the material definition
interface to modify or create a material by clicking button. Refer to Section 8.2.4.2 for a detailed description of
material creation and modification.
GENERAL
This function allows the user to specify a proper position for the defined scrap and set contact between scraps. The Show Scrap option only displays the defined scrap. After this option is toggled on, the defined scraps will be displayed in the display window and the other parts are closed.
MOVE
Adjust the position of each scrap, as illustrated in Figure 10.2.7. Click the Move button to pop up a Move dialog box as illustrated in Figure 10.2.8.
Figure 10.2.7 General Setup
Figure 10.2.8 Move scrap
DESELECT ALL: enables the user to deselect the selected scrap. The button is grey. Once the user selects the scrap, this button will be highlighted.
PICK SCRAP…: enables the user to directly select parts to be moved in the screen window. The user can select parts to be moved directly from the scrap list, or click this button to pop up the Select Part dialog box. The selected parts will be highlighted no matter which selection method is used.
DIRECTION: enables the user to translate scrap along X, Y and Z directions. The user can enter a value in the Distance box. Click the Apply button to confirm or click the Reverse button to reverse the direction.
EXIT: enables the user to exit the Move dialog box.
SET SCRAP CONTACT
This function allows the user to define the
contact between scraps. If this option is toggled on, the define button is
highlighted and the user may define contact according to the requirements.
Refer to Section 8.2.4.2 for a detailed
description.
SINGLE POINT CONSTRAINTS (SPCs)
This function allows the user to define single point constraints. The user may click the Edit… button to display a dialog box illustrated in Figure 10.2.9 Refer to Section 8.2.4.3 for a detailed description of constraint definition.
Figure 10.2.9 SPCs dialog box
In Velocities interface, the user can add or delete velocities, define and edit the initial velocities of scrap, set velocity random, etc. The definition of vertical trim velocity or cam trim velocity can both be completed in this interface. The detailed interface is illustrated in Figure 10.2.10.
Figure 10.2.10 Velocities interface
VELOCITIES LIST
All the currently defined velocity names are listed on the left side of the Velocities dialog box. Among all these velocity names, there is a pressed button which indicates the current velocity. The user may click this button to change the current velocity setting.
NOTE: The newly created velocity label is red, which indicates the velocity definition is not completed. In scrap shedding simulation setup, the user must define each necessary parameter completely. Otherwise, the label remains red to prompt the user to finish the setup.
ADD VELOCITY
This function allows the user to define a new velocity. The user can click the ADD button to switch the interface to Velocities interface, as illustrated in Figure 10.2.11.
Figure 10.2.11 Add velocity
The added Velocities interface and the current Velocities interface are the same. Refer to the current velocity definition for a detailed description.
DELETE VELOCITY
This function allows the user to delete the current velocity. The user can select one velocity from the velocity list as the current velocity. Then click the DELETE button to delete. The program will pop up a prompt dialog box, as illustrated in Figure 10.2.12.
Figure 10.2.12 Delete velocity prompt dialog box
Click OK to delete the current velocity. Click Cancel to cancel the current delete operation. There should be at least one velocity in the velocity list. The user cannot delete all the velocities in the list. If there is only one velocity in the list, the DELETE button is grey and not highlighted.
GENERAL
This function allows the user to define a name for the current velocity. The default velocity names are Vel1, Vel2, Vel3 and etc. Usually, we suggest the user to define a meaningful name for the current velocity, such as vertical or cam, which is more convenient for the user to understand, set and check errors, as illustrated in Figure 10.2.13.
Figure 10.2.13 Velocity name
TIME RELATED LINEAR
This function allows the user to define the time related linear velocity for the edge nodes of scrap contacting the edge of trim tool. Toggle on this option to highlight the button. The Linear Velocity dialog box, as illustrated in Figure 10.2.14will pop up after clicking.
Figure 10.2.14 Linear velocity list
Click the Add… button to define linear velocity. The dialog box is illustrated in Figure 10.2.15. Once the definition is completed, the node number with define velocity and the velocity values along X, Y and Z directions of this node will be displayed in the list. Click the Delete… button to pop up Select Node dialog box for the user to delete the defined velocity for the node.
Figure 10.2.15 Time Related Linear Velocity dialog box
SELECT SCRAP: select scrap part as the object to add velocity.
START NODE: this button is highlighted after the scrap is added. This function allows the user to select the start node of the scrap edge point.
END NODE: this button is highlighted after the scrap is added and the start node is selected. This function allows the user to select the end node of the scrap edge point. Once the selection is completed, the boundary line between start node and end node is highlighted in the display window.
REVERSE: this button is highlighted after the scrap is added and the selection of start node and end node. This function allows the user to reverse the operation of boundary line between nodes until it is confirmed.
NODES NUM: show the number of nodes on the boundary line.
V0: the minimum velocity value added.
Vn: maximum velocity value added.
ASSIGN: allows the user to define boundary line for the selected scrap and velocity, and confirm the operation for the interpolation parameter.
CLEAR: clear the added velocities.
VELOCITY
This function allows the user to define nodes for the current velocity, and define velocity parameters for the selected nodes, as illustrated in Figure 10.2.16.
Figure 10.2.16 Define velocity
The user can add multiple nodes to the current velocity. Click the EDIT button behind Nodes Number to pop up the Velocity Node dialog box illustrated in Figure 10.2.17.
Figure 10.2.17 Velocity node dialog box
SELECT…: add nodes with velocity to be defined. Click this button to pop up the SELECT NODES dialog box.
DELETE: delete nodes in the list. The user can select nodes to be deleted in the screen window or node list and click the DELETE button.
OK: confirm the selected or deleted nodes. Click this button to confirm the operation and exit the Define Node dialog box.
CANCEL: cancel all the operations. Click this button to cancel operations and exit the Define Node dialog box.
If each direction value for the current velocity is confirmed, the user can directly enter the velocity values along X, Y and Z directions. Otherwise, if there is only the press motion curve, the user can click the EDIT button in the Velocity column to pop up the Velocity dialog box, illustrated in Figure 10.2.18.
Figure 10.2.18 Velocity dialog box
TRIM ANGLE
This function allows the user to define the velocity for cam trim. Once the CAM TRIM option is toggled on, the input field for trim angle will be highlighted for the user to input angle value. The default value for ANGLE1 (α) and ANGLE2 (β) is 0. The default value for ANGLE3 (γ) is 25 degrees. The user can define according to the cam angle of the actual tooling.
MOTION CURVE
This function allows the user to read in and view the motion curve and set parameters.
IMPORT: import motion curve of the press. Click this button to display the OPEN dialog box. The format of motion curve is *txt.
VIEW: view motion curve. Click this button to display the LOAD CURVE dialog box. The user can only view motion curve without editing.
SPM (Stroke per minute): stroke per minute. The default is 13. The user is allowed to modify according to practical requirements.
HEIGHT: the trim height of press. The user can define different height corresponding to different press velocity.
APPLY: confirm the parameter setup. After import of motion curve and setup of SPM and HEIGHT, click this button to confirm the setup. The system will automatically calculate the velocity values along X, Y, and Z directions and display them in the velocity column.
VELOCITY
This function can only display the velocity value calculated by the program after the completion of motion curve definition, and it is not highlighted. If the velocity value is changed, the user needs to return to the Velocity dialog box and modify the parameters for calculation.
OK: confirm velocity value. If the displayed velocity value is OK, the user can click this button to exit the dialog box.
CANCEL: the user is allowed to cancel the operation and exit the dialog box.
VELOCITY RANDOM
This function allows the user to set a percentage to offset the current velocity value. After definition of the current velocity, if the user is not sure about this velocity value, he/she can set a percentage to offset the current value.
NOTE: Set a percentage and submit for calculation. The program will automatically write three DYN files. One file has the same name as the current DF file; another file has a suffix _1 with the current DF file name, which means to reduce a certain percentage of the current velocity value; the last file has a suffix _2 with the current DF file name, which means to increase a certain percentage of the current velocity value.
In the TOOLS interface, the user can add, delete and move tools, define tool Part, Position and Contact between blank and tool. The main interface is illustrated in Figure 10.2.19.
Figure 10.2.19 Tools interface
TOOL LIST
All the currently defined tool names are listed on the left side of the Tools dialog box. Among all these tool names, there is a pressed button which indicates the current tool. The user may click this button to change the current tool setting. The user is allowed to select dummy tool and plant line in the interface. In the default tool list, there are three tools: TOOL, DUMMY and PLANT. If there is no selection, there is only one TOOL in the default tool list.
NOTE: The newly created tool label is red, which indicates that the definition of tool parameter is not completed. In the new auto-setup, the user must define each necessary parameter completely. Otherwise, the label remains red to prompt the user to finish the setup.
ADD TOOL
This function allows the user to create a tool in the current setup. The user can click the ADD button to display the Add tool dialog box, illustrated in Figure 10.2.20.
Figure 10.2.20 Add tool dialog box
NEW TOOL
The user is allowed to define a name for the current tool. The default tool name is Tool1, Tool2, Tool3, etc.
DEFAULT SETTING
The user is allowed to set default parameters for the currently created tool, including default settings such as OFFSET. In the default setup, there are three selections: USE SETTING OF TOOL, USE DEFAULT SETTING, and USE AS GUIDE PIN.
USE SETTING OF TOOL: Use the parameters of an existing tool for the new tool. The user can select an existing tool in the pull-down list. The new tool only has the contact setup parameters of the existing tool.
USE DEFAULT SETTING: Use the default parameters to define a new tool. The user can modify each parameter after the new tool is created.
USE AS GUIDE PIN: Define the new tool parameter as guide pin. Refer to the section about guide pin for a detailed description.
APPLY
The user may click this button to create new tool. The new tool will be added to the left tool list.
DELETE TOOL
This function allows the user to delete the current tool. The user can select a tool in tool list as the current tool. Then click the DELETE button to display a prompt dialog box, illustrated in Figure 10.2.21.
Figure 10.2.21 Delete tool prompt dialog box
Click OK to delete the current tool. Click Cancel to cancel the current deleting operation.
TOOL GEOMETRY
This function allows the user to define part for the current tool. The user may add one or multiple parts to the current tool. Clicking the Define geometry… button, the program will pop up a Tool Geometry dialog box. Refer to Section 8.2.4.4 for a detailed description.
After the tool is defined, the parts corresponding to this tool will be displayed in the part list.
POSITION
The user may position the tool by entering the moving distance between tool and HOME position, or click the MOVE button to adjust the position between tools. Show Tool option can only display the defined tool. After this option is toggled on, only the defined tools are displayed in the display window, and the other parts are all closed, as illustrated in Figure 10.2.22.
MOVE
This function enables the user to adjust the position between tools. Clicking the Move button, the system will automatically pop up the Move dialog box. Refer to the section about scrap move for detailed operations.
CONTACT
This function allows the user to define the contact parameter between scrap and the tool involved in calculation. Refer to Section 8.2.4.4 for a detailed description.
DUMMY
This function allows the user to define some dummy tools which actually are not involved in calculation. The remains of the stamped part after scrap shedding and other parts which are not involved in calculation will be kept as DUMMY. This can save calculation time and visually show the relationship between them and scrap as well as tool in the post processor. Dummy tool does not have to define contact parameters. The interface is illustrated in Figure 10.2.23.
Figure 10.2.23 Dummy tool interface
PLANT
This function allows the user to define plant line data. The user may define plant line data according to the requirements, which is to place the plant line hole in a proper position. The interface is illustrated in Figure 10.2.24.
Figure 10.2.24 Plant interface
PLANT GEOMETRY
This function allows the user to define parts for the current plant line. Click the Define geometry… button to display a dialog box, as illustrated in Figure 10.2.25.
Figure 10.2.25 Define geometry dialog box
The user can add plant line hole directly to the list, or click the PLANT LINE button to import from the plant line library file. The library file dialog box is illustrated in Figure 10.2.26.
Figure 10.2.26 Library data dialog box
APPLY
The user can click this button to confirm the read-in data of plant line hole. The data is displayed in the plant line list.
IMPORT
The user can click this button to import the necessary plant line data.
In the Control interface illustrated in Figure 10.2.27, the user is allowed to set some basic parameters to control calculation, including time step setting, output control of database file, etc.
Figure 10.2.27 Control Interface
Set shell edges square: Flag for assuming edge shape for shells when measuring penetration. If this option is toggled on, when submitting for calculation, the program will automatically assume the edge shape for shells to be square. Refer to the LS-DYNA Keyword Manual for detailed description.
Refer to Section 8.2.4.5 for a detailed description of other options.